Register control device for packaging apparatus



1966 s. K. CARLIS LE, JR., ETAL. 3,276,183

REGISTER CONTROL DEVICE FOR PACKAGING APPARATUS Filed March 22, 1963 2Sheets-Sheet 1 EB M INVENTORS.

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2 Sheets-Sheet 2 Q NQ Filed March 22, 1963 United States Patent3,276,183 REGISTER CONTROL DEVICE FOR PACKAGING APPARATUS Sanford K.Carlisle, Jr., Andover, Richard L. Sims, Chelsea, and George H. Hall,Westford, Mass., assignors,

by direct and mesne assignments, to Diamond Crystal Salt Company, St.Clair, Mich., a corporation of Michigan Filed Mar. 22, 1963, Ser. No.267,156 1 Claim. (Cl. 5351) The present invention broadly relates topackaging apparatus for making containers or packets of the typeemployed for dispensing individual servings of various commodities suchas spices, sugar, salt, and the like and more particularly to a novelregister control device for maintaining a printed web in appropriateregistered alignment with and centered relative to a second web whichsubsequently are united for forming the container.

The register control device comprising the present invention isparticularly applicable to high speed automatic packaging machines ofthe general type described in U.S. Patent No. 2,826,020, granted March11, 1958. In machines of this general type, a continuous compo-siteribbon is manufactured by combining two continuous webs or strips of theappropriate configuration which are secured to each other after whichthe continuous ribbon is filled with a desired commodity, sealed andthereafter is cut into individual packages or containers. In anapparatus of this type, the rate of production is extremely high and thetwo Webs move rapidly through the apparatus at speeds usually greaterthan 75 feet per minute. It is frequently desirable to imprint or embossone of the webs of which the package is comprised with suitable indiciasuch as instructions in the use of the package or in advertising subjectmatter. Because of the high rates of speed involved and due to thefluctuations in the physical properties of the web material asinfluenced by its composition, structure, and surrounding atmosphericand temperature conditions, it is extremely difficult to synchronize themovement of the printed web relative to the second web so as to assurethat the indicia will at all times remain centered on the resultantindividual package. When the imprinted web moves out of registrysubsequent cutting of the continuous strip into individual packets ordispensing containers results in a mutilation of the imprinted messagewhich seriously detracts from the appearance, informative nature, andusability of the package.

Because of this problem it has been conventional in the past to form thecontinuous strip from two webs wherein the imprinted or embossed indiciahas a spacing frequency of greater than two per width of the finalpackage to assure that a complete message or design is incorporated oneach package. Alternatively, the continuous strip is formed of twounprinted webs and the individual packages cut therefrom are thereaftersubjected to a second operation in which an imprinted or embossedoverlay web is placed and adhesively secured to the face of eachindividual packet in appropriate centered relationship. This latterpractice is extremely costly, tedious and time consuming andsubstantially detracts from the efliciency and economy of the operation.

It is accordingly a principal object of the present invention to providea register control device for accurately controlling the registration ofimprinted or embossed indicia on one web relative to the resultantpackage so as to assure a centering of that message thereon.

Another object of the present invention is to provide a web having aplurality of repetitive indicia thereon which are disposed on arepetitive spacing increment less than the width of the resultantpackage and providing for controlled tensioning means for stretching theimprinted or embossed web into appropriate register with the resultantpackage.

Still another object of the present invention is to provide an improvedregister control device for packaging apparatus which is completelyautomatic and which is operative to maintain two webs in appropriateregistered relationship and which device is of simple control, durableconstruction, and efiicient and economical operation.

The foregoing, and other objects and advantages of the present inventionare achieved by providing a continuous web having a repetitive patternof embossed or printed indicia thereon which are spaced at -a frequencyof a controlled increment less than the width of the final individualpackage and which web is fed through a supply system incorporatingautomatic variable tensioning means therein for stretching the web to agreater or lesser magnitude to maintain appropriate registration of thepattern thereon relative to a second strip in response to sensing meansoperatively associated with the tensioning means.

Other objects and advantages of the present invention will becomeapparent on the reading of the following specification taken inconjunction with the accompanying drawings in which:

FIGURE 1 is a schematic elevational view of an exemplary packagingapparatus to which the present invention is applicable;

FIGURE 2 is a fragmentary perspective view of a continuous web having arepetitive imprinted or embossed pattern thereon and provided withregistration marks at preselected intervals therealong;

FIGURE 3 is a perspective view of an individual dispensing package madein accordance with the machine shown in FIGURE 1;

FIGURE 4 is -a horizontal sectional view of the package shown in FIGURE3 and taken along the line 4-4 thereof;

FIGURE 5 is an elevation view of the back surface of the package shownin FIGURE 3, illustrating an imprinted pattern substantially centeredrelative to the side edges of the package;

FIGURE 6 is a fragmentary side elevation view of the package formingapparatus shown in FIGURE 1, and a diagrammatic view of the wiringcircuitry associated therewith for providing automatic register controlof a web relative to the side edges of a package being formed;

FIGURES 79 .are diagrammatic views of the relationship between thesquare wave forms created by a rotary selector switch and aphotoelectric sensing device when the web is in a registered, advanced,and retarded position, respectively, relative to the side edges of apackage; and

FIGURE 10 is a fragmentary side elevation view partly in section of thebraking roll provided with a magnetic brake mechanism for applying apreselected control braking force thereto.

The automatic register device comprising the present invention ispredicated on the principle that thin sheets or film material includingpaper and plastic materials, for example, possess an inherent degree ofresiliency enabling a controlled elongation or stretching thereof responsive to a controlled tensioning of the web. The stretchability ofsuch materials is affected by numerous factors including variations inthe structure and compositions of the sheet stock, the type andthickness of coatings applied on the surfaces thereof, the humidity andtemperature of the environment, etc. These factors are particularlypronounced in coated-one-side paper stock which comprises an eminentlysatisfactory material of which individual dispensing type packages aremade.

The stretchability aspects of the imprinted or embossed web coupled witha preselected spacing interval of the imprinted or embossed patternrelative to the width of the package provides the means for effectingdynamic controlled advancement or retardation of the web relative to thepackage maintaining appropriate dynamic registry of the pattern relativeto the edges of a final package. In accordance with this relationship,the web is imprinted or embossed with a repetitive pattern spaced atintervals which are slightly smaller than the width of the resultantpackage. The differential between the pattern width and resultantpackage width will vary depending on considerations such as the degreeof stretchability of the web, the size of the package being formed, andthe accuracy of registration required. In the manufacture of fluted typedispensing packages of the type shown in FIGURE 3 having a width in theorder of 1% inches and employing a web comprised of paper provided witha thermoplastic resin coating on one surface thereof, it has been foundthat imprinting r embossing the pattern repeat in an interval of severalthousandths of an inch shorter than the width of the resultant packageprovides for satisfactory control of the registration of the webrelative to the package.

Because of the shorter distance between pattern repeats, the imprintedweb will have a natural tendency to advance relative to the second webof which the package is comprised. Advancement of the imprinted webrelative to the second web beyond a preselected magnitude can becorrected by applying a preselected corrective tension to the imprintedweb effecting a stretching or elongation thereof wherein movement of theimprinted web is retarded relative to the second web bringing the twowebs back into registry. In accordance with the present invention thisis achieved by applying a preselected tension for a predetermined timeperiod during which the imprinted web is retarded relative to the second web. At the completion of the corrective tensioning of the imprintedweb, the tension is released and the imprinted web again commences toadvance into registration and beyond registration at which pointcorrective action is again applied. In accordance with the preferredpractice of the present invention, a base or pilot tension iscontinuously applied to the imprinted web which is periodicallysupplemented by the corrective tension to maintain the two webs inappropriate register. Movement of the imprinted web to an advancedposition can suitably be detected by sensing means such as aphotoelectric cell operative to read registration indicia imprnted onthe imprinted or embossed web which electrically communicates thisinformation to a suitable control circuit which is operative to applythe appropriate corrective action in a manner subsequently to bedescribed.

Fluted dispensing packages of the type shown in FIG- URE 3 can beconveniently made in accordance with the apparatus as schematicallyshown in FIGURE 1 which is of the type more fully shown and described inthe aforementioned United States patent to which reference is made for amore detailed discussion of the individual components thereof. As shownin FIGURE 1 the exemplary machine comprises a pair of cooperating rolls12, 14 which are rotatably mounted for rotation about substantiallyhorizontal axes and which rolls are provided with a plurality ofprojections 16 and identations 18 of substantially semi-circular crosssection extending longitudinally along the peripheral surfaces thereof.The projections 16 and recesses 18 are arranged in a plurality of seriesusually ranging from about 2 up to about 6 and are separated by spacesgreater than those between the projections of each series forming planarweb sections indicated at 20 in FIGURE 3. A continuous strip 22 isadvanced over a roll 24 and passes through a guide shoe 26 through whichthe strip is advanced in alignment into the bite portion of thecooperating rolls 12, 14 as shown in FIGURE 1.

The conjugate meshing relationship between the projections and therecesses of the cooperating rolls imparts a preselected corrugated orfluted pattern to the strip 22.

A second or imprinted strip 28 is advanced around a guide roll 30 andextends therefrom around the lower portion of a roll 32 disposed inbearing contact against the periphery of the cooperating roll 14. Inaccordance with this arrangement the second continuous strip 28 ispositioned in overlying contact with the first corrugated strip 22 andthe strips are tenaciously united to each other such as by means of asuitable adhesive or by heat sealing the two strips together. In orderto effect a heat sealing of the strips 22, 28 the mating surfacesthereof are provided with a thin coating of a suitable thermoplasticresin material such as polyethylene or polyvinyl chloride, for example,which on passing over the heated rolls 14 and 32 are heat softened andbecome tacky effecting adherence of the two strips at their points ofcon tact which on subsequent cooling form a unitary com positecontinuous fluted ribbon indicated at 34.

The fluted ribbon 34 thereafter passes upwardly and around a guide roll38 and passes between a pair of crimping rolls 39 compressing and heatsealing the two strips to each other forming a sealed edge indicated at36 in FIGURE 3 along the lower edge of the fluted ribbon. The ribbon isthereafter twisted toward a substantially upright position as it passesbeneath a filling hopper 40 from which a suitable commodity is dispensedeffecting a filling of the interiors of the individual flutes 42 as bestseen in FIGURE 4. On passing beyond the filler hopper 40 the upper openedge of the fluted ribbon 38 passes between a pair of heated crimpingrolls 44 effecting a sealing of the upper edge thereof along an edgeindicated at 45 and hermetically sealing the commodity within theflutes. The filled and sealed fluted ribbon is thereafter twisted to aposition where the flutes are disposed on the underside thereof and thecontinuous ribbon is trained around an indexing roll indicated at 46formed with a plurality of projections and depressions corresponding tothe corrugated configuration of the continuous ribbon. A cutter roll 48which is mechanically coupled to the indexing roll 46 is operative tosever the continuous ribbon at a point substantially midway of theplanar web sections 20 forming therewith individual packets or packages50 of the type shown in FIGURE 3. The flutes 42 of the package 50 may beprovided with a series of transverse slits or perforations 52 tofacilitate subsequent rupture of the package for shaking or dispensingthe contents therefrom.

The mechanical cutter arrangement assures that severance of thecontinuous fluted ribbon will occur at a point substantially midwaybetween each of the intervening flat planar sections which in turndefine the width of the resultant individual dispensing packages. Itwill accordingly be appreciated that when an imprinted web or strip 28is employed as shown in FIG. 2 which is provided with a repetitiveimprinted or embossed pattern indicated at 54, it is necessary tomaintain appropriate registration of the patterns 44 relative to theplanar web sections 20 so as to assure a centering of the pattern 54 insubstantially the center of the package 50 as shown in FIG. 5.Registration of the imprinted web 28 relative to the cleveage pointsdefining the side edges of the package will now be described withparticular reference to FIG. 6.

As shown in FIGURE 6, the imprinted continuous strip 28 is supplied froma feed roll 56 and extends therefrom over a fixed guide 58; up over asnubber pulley 60; around and between a brake roll 62 and pinch roll 64;up and around an infeed-guide roll 66; and thence around the roll 32 ashereinbefore described. The strip 22 similarly extends in a continuousmanner from a feed roll 68; over the guide roll 24; through the guideshoe 26 and between the cooperating forming rolls 12 and 14 aspreviously described. The advancement of the strip 28 having animprinted repetitive pattern thereon is dynamically contnolled relativeto the corrugated configuration imparted to the strip 22 by thecooperating rolls 12 and 14 such that the two strips as they advanceinto overlying relationship at the bite of the rolls 14 and 32 aredisposed in appropriate registration relative to each other.

This registration is achieved by applying a preselected correctivebraking action to the brake roll 62 in response to sensing means such asa photoelectric eye 70 mounted on the frame of the machine which isadapted to sense the relative disposition of suitable illuminatedindicia such as the registration marks 72 as best seen in FIGURE 2 whichare imprinted at preselected intervals along the edge of the continuousstrip 28. The registration marks 72 are preferably located substantiallymidway between the patterns on the printed strip 28 such that they willbe located along the line of severence of the continuous ribbon and layon the edge of the packets formed. I-llumination of the strip 28 as itpasses before the photoelectric eye 70 is achieved by a lamp 74whereupon variations in the reflected light received by thephotoelectric eye is transmitted to a registration control unitindicated generally at 76. The location of the focal point of thephotoelectric eye 7 0 is established by a definite mechanicalrelationship which is correlated with the disposition of the depresisonsand projections on the forming rolls 12 and 14 such that when thebacking strip 28 is in register with the fluted strip 26, thephotoelectric eye 70 will sense the presence of a registration mark 72on the strip 28 passing before the photoelectric eye 70. The mechanicalplacement of the photoelectric eye can be conveniently achieved byspacing it one or a multiple of the distances between registration marksfrom the point of tangential contact of the forming roll 14 and guideroll 32 at which the two strips are mated to each other.

The current impulse transmitted by the photoelectric eye to the registercontrol unit 76 is correlated with a current impulse transmitted from arotary selector switch 96 (FIGURE 6) of the type well known in the artwhich is mechanically driven by the forming rolls 12 and 14 and isoperative to close its contact each time the forming rolls 12 and 14have rotated through a peripheral distance corresponding to theformation of a series of packages equivalent to the spacing betweenregistration marks 72 on the backing strip 28. The closing of theselector switch contact is mechanically coupled so as to occur atsubstantially the midpoint of the formation of the planar web section20. Each time the selector switch point closes a pulse is sent to theregister control unit which analyzes the pulse transmitted therebyrelative to the pulse received from the photoelectric eye to determinewhether any corrective action is required.

The register control unit 76 is of a type well known in the art and adetailed discussion thereof is not necessary for a full understanding ofthe present invention. Suflice it to say that the register control unitoperates as a simple rate of change amplifier effecting amplification ofthe pulse received from the photoelectric eye and the rotary selectorswitch which in turn is capacity coupled to a thyratron tube. If theamplified pulses received are in appropriate position indicatingappropriate register a rejection of the amplified pulse occurs. On theother hand, if the pulses overlap indicating an advanced position of thebacking web relative to the corrugated web, the amplified pulse isswitched to fire the thyratron tube which actuates a double polecontactor applying additional resistance to the circuit andsimultaneously starts an electronic resistance-capacitance type timerfor maintaining the resistance in the circuit for a preselected timeperiod. At the expiration of the timed interval, the contactor isdeenergized and the thyratron tube is reset preparatory for the nextoperation. A commercially availablennit suitable for this purpose is aFisher-Pierce #4412 control unit.

During the timing interval corrective action is applied comprisingenergization of a suitable braking mechanism such as a magnetic brake 78coupled to the brake drum or roll 62 applying a preselected increasedtension and effecting stretching of the backing strip 28 achieving acontrolled retardation thereof relative to the fluted strip 22. Theinherent tendency of backing strip 28 to advance in accordance with theshort-printing of the repetitive pattern thereon effects progressiveadvancement of the backing strip to a point where corrective action isagain required in a manner as previously described.

The foregoing comparison of the square wave forms analyzed by theregister control unit can best be described in connection with FIGS.7-9. As shown in FIG. 7 the register control unit receives the squarewave impulse from the selector switch and the square wave impulse 82from the photoelectric eye which are illustrated in the registeredcondition wherein the trailing edge of the square wave 80 is disposedjust ahead of the leading edge of the square wave 82. In accordance withthe backing strips natural tendency to advance, the square wave 82 asshown in FIG. 8 moving in the direction of movement of the imprinted webas indicated by the arrow overlaps the trailing edge of the square wave80 which effects a firing of the thyratron tube applying a correctivetensioning or stretching action of a preseleced magnitude for apredetermined time period effecting a retardation of the web such thatthe square wave forms 80 and 82 assume a slightly retarded position asillustrated in FIG. 9. The natural tendency of the backing web toadvance thereafter achieves advancement toward the completely registeredposition illustrated in FIG. 7 followed thereafter by furtheradvancement to the position shown in FIG. 8 wherein a subsequentcorrective action is again taken.

The operation of the machine will now be described with particularreference to the wiring diagram as illustrated in FIG. 6. The circuit isenergized by the closing of manual contact S1 whereby an alternatingcurrent is transmitted thru conductors L1, L2 effecting illumination ofon-off indicator light 84 and simultaneously energizing electric motor86 which is drivingly coupled to the form rolls effecting advancement ofthe strips 22, 28, and the composite fluted ribbon 34. A preselectedpilot braking or base drag is applied to the magnetic brake 78 by avariable resistor R1 to effect a slight tensioning of the backing strip28 avoiding any slack therein. The magnitude of the pilot tensionapplied can be controlled by adjusting the variable resistor R1 so thatan initial stretch is applied to the imprinted web. The initial stretchis of a magnitude less than the difference between the pattern repeatand the width of the final package to maintain the inherent advancingcharacteristics of the imprinted web relative to the fluted pattern ofthe first web.

During initial start-up of the machine, the pilot tension is undesirableand frequently occasions rupture of the backing strip 28. Accordingly, asuitable time delay switch S4 is preferably employed in the circuitcompris ing a filament 88 which is comprised of a bimetallic strip andupon heating for a preselected time period is operative to open contact90 placing the variable resistor R1 in series with the control circuit.During the initial startup, contact 90 is in the closed positionshunting the resis tors R1 and R2 thereby increasing the bias voltageand substantially eliminating the transmission of any current to themagnetic brake 78 and eliminating any drag on the printed web 28.

In accordance with the preferred practice of the present invention aregulated DC. voltage power supply unit 92 is provided to assure aconstant source of DC. voltage in spite of fluctuations in the linevoltage. The voltage control unit 92 is electrically connected to themagnetic brake 78 by mean-s of conductors 94 as shown in FIG. 6. Thevoltage control unit 92 may be of any of the types well known in the artsuch as a model commercially designated as ABC 15-1, (-lM) sold byKepco, Inc. of Flushing, NY. As hereinbefore set forth, on the openingof contact 90, the pilot or base voltage is applied to the magneticbrake 78 applying a preselected initial tension to the backing strip 28.The pilot tension can be selected by varying the variable resistor R1which provides an initial stretch to the strip preventing an excessivedegree of relative advancement thereof, thereby avoiding the necessityof over-corrective control by the system,

A rotary cam operated selector switch 96 of the type well known in theart is drivingly coupled by a reference shaft to the forming rolls 12and 14. In the specific switch shown, two cams 98 are included which areoperative to actuate breaker point contacts 100?, 102 respectively.Contacts 102 are electrically connected to the register control unit 76for forming the square wave impulse for comparison with the square waveimpulse received from the photoelectric cell. Contacts 100 areelectrically connected to line L2 by conductor 104 and to coil 106 of acontrol relay 107 indicated in dotted lines. The coil 106 in turn iselectrically connected to line I11 by means of conductor 108. The relayis provided with a pair of normally opened (N.O mechanically coupledcontacts 110, 112 which are normally biased toward the open position.The contacts 110, 112 are closed in response to the energization of thecoil 106 responsive to the closing of contacts 100 of the rotaryselector switch 96. On closing of contact 110, timing light 114 isilluminated for an instant which visually signals the operator that aregistration mark 72 should be positioned in alignment with a suitablereference mark at a preselected point along the machine such as at thevertical center line or the input feed roller 68 as shown in FIGURE 6.The timing light 114 facilitates initial registration during adjustmentand start-up of the apparatus. The contact 112 of the relay 107 iselectrically connected to a plug P1 adapted to receive a jack of astroboscope, if desired, to facilitate alignment and adjustment of theapparatus as may be required from time to time.

During initial start-up of the machine, a discrepancy in theregistration between the backing strip 28 and the edges of the packagecan be manually corrected by means of manual advance switch S3 andnormally closed manual retard switch S2. For example, if the backingstrip is excessively retarded, normally open advance switch S3 can beclosed shunting the pilot resistor R1 thereby removing pilot brakingfrom the magnetic brake and effecting rapid advancement of the backingstrip 28 in accordance with its inherent advancing tendency. On theother hand, if the backing strip is substantially advanced, normallyclosed retard switch S2 can be manually opened for a preselected timeperiod impressing resistors R1 and R2 across the circuit applying acombined pilot braking and corrective braking force to the magneticbrake 78 effecting a rapid retarding of the backing strip intoregistration. On subsequent release of the manual advance switch S3 ormanual retard switch S2 the control system assumes its normal automaticregister action.

When the backing strip 28 advances to a position at which the thyratrontube is fired, a control relay or contactor (not shown) within theregister control unit 76 is opened whereby corrective resistor R2 isplaced in series with pilot resistor R1 applying an increased correctivevoltage to the magnetic brake 7-8 and increasing its braking force.During the corrective time delay period, correction indicator light 116is illuminated to visually advise the operator of the action takingplace. The magnitude of corrective braking action applied can be variedby adjustably positioning the variable resistor R2 and by ad justing thetimer in the register control unit for the duration in which thecorrective braking action is applied. Accordingly, but adjusting thevariable resistors R1 and R2 and the timer, the frequency of correctiveaction and the limits of accuracy within which the two webs aremaintained in registry can be accurately controlled.

In the exemplary embodiment illustrated in FIGURE 10 a magnetic brake 78of the type well known in the art is illustrated comprising a rotor 118coupled to a shaft 120 on which the brake roll 72 is affixed. A stator122 surrounds the rotor 118 and is secured by means such as an arm 124to the frame or stationary portion of the machine. The stator 122 isprovided with a coil 126 to which the pilot current and correctivecurrent is applied for magnetizing magnetic particles .128 disposedbetween the stator and rotor increasing frictional rotative resistancetherebetween and increasing resultant braking action of the brake.Alternate suitable braking devices such as servo-actuated mechanicalbrakes as well as fluid brakes of the types Well-known in the art can besatisfactorily employed in lieu of the magnetic brake herein show anddescribed.

While it will be apparent that the embodiments of the invention hereindisclosed are well calculated to fulfill the objects of the invention,it will be appreciated that the invention is susceptible tomodification, variation and change without departing from the properscope or fair meaning of the subjoined claim.

What is claimed is:

An apparatus for making fl-uted packets having registered indicia on thefaces thereof comprising a pair of forming rolls disposed in rollingengagement and having a conqjugate repetitive contour on the peripheriesthereof, first feed means for continuously feeding a first strip betweensaid rolls and imparting an embossed configuration thereto reoccurringat fixed spaced intervals, switch means drivingly coupled to said rol-lsfor signaling the dynamic position of said embossed configurationrelative to a reference point, second feed means for feeding a secondstrip in overlying bonded relationship to the said first strip formingtherewith a composite ribbon, said second strip provided with arepetitive pattern thereon disposed at a spacing frequency shorter thansaid fixed spaced intervals of said embossed configuration and furtherprovided with registration marks therealong disposed at preselectedfixed intervals, said second feed means including brake means forintermittently applying a preselected tension to said second stripeffecting a stretching of the pattern thereon to a width greater thansaid fixed spaced intervals of said embossed configuration, sensingmeans for sensing the dynamic position of said registration marks onsaid second strip relative to said reference point, control meansopcratively associated with said switch means and said sensing means forintermittently energizing said brake means for a predetermined timeperiod responsive to the advancement of said pattern on said secondstrip a preselected increment out of registration relative to saidembossed configuration on said first strip, means for filling andsealing said ribbon, and cutter means for severing said ribbon atintervals corresponding to said fixed spaced intervals of said embossedpattern forming therewith a plurality of individual packets.

References Cited by the Examiner UNITED STATES PATENTS 2,375,451 5/1945Waters 53 51 2,546,059 3/1951 Cloud 53 51 2,826,020 3/1958 Hoag 53 2s3,140,573 7/1964 Buttolph 53 51 FRANK E. BAILEY, Primary Examiner.

TRAVIS S. MCGEHEE, Examiner.

G. T. COOGAN, L. S. BOUCHARD,

Assistant Examiners.

